Disposable Electrolytic Cell with Bi-polar Electrode, and Method of Use Thereof

ABSTRACT

An electrolytic cell that generates metal hydroxides from metallic anode material utilizing small metal particles or fines. Metal fines are impregnated in an open cell or reticulated foam material and rolled into a cylindrical shape having a fixed electrode in the center and on the outer surface of the cylinder. Basket cells with larger metal pieces disposed therein in a packed bed configuration may alternatively be utilized.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part application of U.S. Provisional Application Ser. No. 61/414,352, entitled “Disposable Electrolytic Cell Configurations and their Bi-polar Electrode Profiles”, filed Nov. 16, 2010, and claims priority thereto and the full benefit thereof. Application 61/414,352 is incorporated herein by reference.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT None PARTIES TO A JOINT RESEARCH AGREEMENT None REFERENCE TO A SEQUENCE LISTING None BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates generally to electrolytic cells, and more specifically to a disposable electrolytic cell that utilizes metallic particles and fines, utilized in treating wastewater.

2. Description of Related Art

The treatment of wastewater often requires the use of a polymer or metal hydroxide to coagulate the colloidal solids so that they can be filtered and/or removed from the system. Coagulants can be produced electrolytically by a process known as electro-coagulation.

Numerous types of wastewater treatment systems exist, some of which employ electro-coagulation. Electro-coagulation has been proven for many years to be an excellent method for the coagulation and oxidation of solids in wastewater versus the use of chemicals and biological means to do the job. However, one set of the problems has been the cost and maintenance of the cells used, and this has kept this technology from commercial use.

Historically, systems employing electrolytic technology have had other disadvantages, namely, an impermeable oxide film forms on the cathode leading to the loss of cell efficiency and requiring frequent maintenance which is time consuming and costly, and analyzing cell efficiency and maintaining efficiency is often not addressed. Electrolytic cells are generally utilized for the treatment of wastewater to produce polymer or metal hydroxide to coagulate the colloidal solids. Typically, the electrolytic cells are utilized to generate metal hydroxides from metallic anodes.

Conventional electrolytic cells consist of plates that are stacked or positioned so that the electrolyte passes between the plates. Other profiles may use anodes of ¼″ to ½″ in a packed bed electrolytic cell. However, current cell designs using plates are not energy efficient and require costly maintenance in order to keep the cell operating for long periods of time. Unfortunately, plate style electrodes (anodes) do not decompose completely before they need to be serviced or replaced.

Electrolytic coagulation and oxidation take place in a cell where electrical current is passed between the anode and cathode. During the exchange of electrons, the anodes decompose to form a metal hydroxide while the cathode is coated with a non-conductive film. It is the decomposition of the anode that produces the metal hydroxide used to coagulate the suspended particles in the electrolyte (wastewater).

While other methods have attempted to solve these problems, none have utilized or disclosed a system or method utilizing a disposable electro-coagulation cell and analytical system.

Therefore, it is readily apparent that there is a need for an electrolytic cell that will produce metal hydroxides in solution more efficiently than the use of chemical coagulants or other types of electrolytic cell equipment.

BRIEF SUMMARY OF THE INVENTION

Briefly described, in a preferred embodiment, the present invention overcomes the above-mentioned disadvantages and meets the recognized need for such a device by providing disposable electrolytic cells that are designed to utilize small metal pieces and fines as bipolar electrodes in a packed bed configuration, and to utilize scrap metal as anodes in a disposable basket or cartridge, thereby eliminating the high cost of maintenance and improving the energy efficiency associated with the decomposition of metal to its hydroxide form. The use of metal pieces or fines that decompose completely and do not need to be serviced before they are discarded, contrasts with the high cost of service needed to maintain a plate system.

According to its major aspects and broadly stated, the present invention in its preferred form is a disposable electrolytic cell that produces metal hydroxides in solution from metal fines more efficiently than the use of chemical coagulants or other types of EC equipment. The metal fines are impregnated in an open cell or reticulated foam material and rolled into a cylindrical shape having a fixed electrode in the center and outer portions of the cylinder. An electrolytic sponge allows the use of metal fines that decompose completely. Basket cells with larger metal pieces disposed therein in a packed bed configuration may alternatively be utilized. Further, the electrolytic sponge or basket cells are disposable.

More specifically, the disposable electrolytic cell allows the use of metal fines that are more energy efficient in their decomposition than chemical coagulants or other types of EC equipment.

The open cell foam or sponge is fabricated from any materials that allow the metal fines to migrate throughout the cellular structure. Any sponge or open cell material is utilized that can be cut or fashioned into any shape and inserted into a housing that will accommodate the introduction of wastewater (electrolyte) and allow the bipolar electrodes to react upon application of an electric current.

The metal fines comprise any metal type or non-metal material, such as, for exemplary purposes only and without limitation, machining shavings or particles that are smaller than the pore size of the cell structure in the open cell material. The cell structure holds the metal particles in place after the material is rolled into cylinder. The electrolytic sponge or basket cells hold the metal fines or non-metal material in the reactive range of the cell. Since the sponge has two sides, the interior is accessible from either side resulting in a bipolar electrode.

Disposable basket and cartridge cells hold the metal pieces and fines in the reactive zone of the cell. Bipolar electrodes have a greater surface area for the space they occupy and take less energy to decompose to a metal hydroxide than the most common plate cell configuration.

Electrolytic sponge may alternatively be utilized in a plate configured cell or in any shape to accommodate the movement of water through the sponge while introducing an electrical current through the cell.

As the anodes decompose, the cathode in the same cell is coated with a resistive film that prevents the passage of current and the decomposition of the anode over time. This coating of a resistive film takes place at a slower pace as the size of the anode decreases, resulting in complete decomposition before replacement becomes necessary.

Accordingly, disposable electrolytic cells lower fabrication and maintenance costs by using low cost expendable materials. The anodes used in the disposable cells are generally produced from scrap metal chips, turnings and fines generated from machining metal parts. Small pieces of metal can be decomposed more quickly with less energy than solid plates. Efficiency in energy to decompose metal in an electrolyte (water) is directly related to the profile of the electrodes (bipolar anodes) utilized in the electrolytic cell. The more surface area exposed to the exchange of electrons, the higher the efficiency achieved in decomposition (consumption) of the metal (anode) to the hydroxide state.

To make the disposable electrolytic cells of the preferred embodiment, the open cell foam or sponge like materials are impregnated with metal fines or any conductive materials. After the sponge or open cell material is impregnated with metal fines, the sponge or open cell material is cut and/or fashioned into a selected shape and inserted in the housing, wherein the housing accommodates the introduction of wastewater (electrolyte) and permits electrical connections to the fixed electrodes.

The impregnated sponge is rolled around a fixed electrode (bar or pipe) until it forms a cylinder of the desired size to fit into the housing, much like a filter cartridge. The outside of the cylinder is wrapped with a perforated metal screen and the cartridge is inserted into the housing. The inner and outer fixed electrodes are subsequently connected to a power source.

Accordingly, a feature and advantage of the present invention is its ability to be utilized in any industry where the production of a metal hydroxide, oxygen or hydrogen may be required.

Another feature and advantage of the present invention is its ability to eliminate the maintenance associated with electrodes in electrolytic cells.

Still another feature and advantage of the present invention is its ability to quickly replace disposable electrolytic cells.

Yet another feature and advantage of the present invention is that low cost electrolytic cells can be manufactured as disposable baskets or cartridges.

Yet still another feature and advantage of the present invention that it automatically connects disposable electrolytic cells without hard wiring.

A further feature and advantage of the present invention is its ability to pass an electrolyte (wastewater) through a cell without restricting the flow.

Still a further feature and advantage of the present invention is that it can utilize inexpensive scrap anode materials.

These and other features and advantages of the present invention will become more apparent to one skilled in the art from the following description and claims when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention will be better understood by reading the Detailed Description of the Preferred and Selected Alternate Embodiments with reference to the accompanying drawing figures, in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

FIG. 1 depicts a cross-section of reticulated or open cell foam impregnated with metal fines to form an anode according to a preferred embodiment;

FIG. 2 is a top edge view of the impregnated foam or open cell material anode rolled around a perforated cathode to form a cartridge cell according to a preferred embodiment;

FIG. 3 is a top view of an electrolytic sponge cartridge having a tubular cathode at the center within the anode and a perforated metal cathode at the outer surface of the anode according to a preferred embodiment;

FIG. 4 depicts a cartridge (disposable electrolytic sponge) with wastewater flow passing through the cartridge from the center perforated influent tubular electrode to outside according to a preferred embodiment;

FIG. 5 shows a pressurized housing with an e/sponge cartridge and means to change the e/sponge cartridge without major mechanical dismantling and without interrupting the process flow according to a preferred embodiment;

FIG. 6 shows a low pressure housing for a quick change of the e/sponge cartridge and further shows the position of a flow restrictor to eliminate high flow, high pressure conditions according to a preferred embodiment;

FIG. 7 shows the high pressure housing utilized with a basket cell having a hold down clamp to secure the cap and bottom power connections according to a preferred embodiment;

FIG. 8 shows an air-operated cap removal tool utilized to quickly remove the cap in order to replace the basket cell according to a preferred embodiment;

FIG. 9 shows a disposable basket cell that is utilized to hold bipolar electrodes in a packed bed configuration according to a preferred embodiment;

FIG. 10 shows a metallic fabric basket sitting on the electrical contacts eliminating hard wired connections according to a preferred embodiment;

FIG. 11 shows the bipolar electrode profiles and how they react in a packed bed electrolytic cell according to a preferred embodiment;

FIG. 12 is a graph showing the energy efficiency with regard to the decomposition of metal to the hydroxide form and electrode profiles using Plates, Chips, Spheres and Fines according to a preferred embodiment.

FIG. 13 depicts an exploded view of the removable basket according to a preferred embodiment;

FIG. 14 is a cross-sectional view of a disposable electrolytic cell with twist-off cap, quick connector and flow restrictor according to an alternate embodiment;

FIG. 15 depicts a cross-sectional view of a disposable electrolytic cell with detail of a disposable basket liner according to an alternate embodiment;

FIG. 16 depicts an anode mix/blend configuration in a packed bed electrolytic cell; and

FIG. 17 is a cross-sectional view of an electro-coagulation cell efficiency analyzer.

DETAILED DESCRIPTION OF THE PREFERRED AND SELECTED ALTERNATE EMBODIMENTS OF THE INVENTION

In describing the preferred and selected alternate embodiments of the present invention, as illustrated in FIGS. 1-17, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions.

Referring now to FIGS. 1-4, the present invention in a preferred embodiment is a disposable electrolytic sponge cartridge comprising an anode formed from an electrolytic sponge, for exemplary purposes only, a reticulated or open cell foam impregnated with metal particles, such as, for exemplary purposes only, metal fines. The electrolytic sponge is rolled around, and is in electrical communication with, a perforated tubular electrode, thereby forming the anode. The anode is subsequently inserted into a perforated tubular cathode.

The anode and cathode are in electrical communication with a power source, wherein the anode is connected to the negative terminal of the power source and the cathode is connected to the positive terminal of the power source.

Turning now more particularly to FIG. 1, depicted therein is a cross-section of reticulated or open cell foam impregnated with metal fines to form an anode according to a preferred embodiment.

Turning now more particularly to FIG. 2, depicted therein is a top edge view of the impregnated foam or open cell material anode rolled around a perforated cathode to form a cartridge cell according to a preferred embodiment.

Turning now more particularly to FIG. 3, depicted therein is a top view of an electrolytic sponge cartridge having a tubular cathode at the center within the anode and a perforated metal cathode at the outer surface of the anode according to a preferred embodiment.

Turning now more particularly to FIG. 4, depicted therein is a cartridge (disposable electrolytic sponge) with wastewater flow passing through the cartridge from the center perforated influent tubular electrode to outside according to a preferred embodiment. The power connections are made at the bottom of the cartridge so that the connections are made when the cartridge is placed in the housing, eliminating the need for “hard wired connections”.

Turning now to FIGS. 5-15, to assist in replacement of active components the cap on the housing screwed on in order to make access quick and easy, allowing the entire operation to take in no more than 1 minute per cell, as depicted in FIGS. 5, 6, 7 and 14.

Turning now more particularly to FIG. 5, depicted therein is a pressurized housing with an e/sponge cartridge and means to change the e/sponge cartridge without major mechanical dismantling and without interrupting the process flow according to a preferred embodiment; FIG. 5 further shows quick electrical connections that are made automatically when the cartridge is replaced.

Turning now more particularly to FIG. 6, depicted therein is a low pressure housing for a quick change of the e/sponge cartridge and further shows the position of a flow restrictor to eliminate high flow, high pressure conditions according to a preferred embodiment; FIG. 6 further shows the power connections at the bottom of the housing to eliminate hard wired connections.

Turning now more particularly to FIG. 7, depicted therein is the high pressure housing utilized with a basket cell having a hold down clamp to secure the cap and bottom power connections according to a preferred embodiment; FIG. 7 further shows quick connectors to remove the housing without disrupting the process flow.

Turning now more particularly to FIG. 8, depicted therein is an air-operated cap removal tool utilized to quickly remove the cap in order to replace the basket cell according to a preferred embodiment.

Turning now more particularly to FIG. 9, depicted therein is a disposable basket cell that is utilized to hold bipolar electrodes in a packed bed configuration according to a preferred embodiment; The basket cell of FIG. 9 is comprised of a fabric basket with a fixed electrode at the center of the basket and a perforated fixed electrode encasing the basket.

Turning now more particularly to FIG. 10, depicted therein is a metallic fabric basket sitting on the electrical contacts eliminating hard wired connections according to a preferred embodiment. The metallic fabric basket eliminates the need for a separate perforated metal electrode to encase the basket. FIG. 10 further shows the housing as it sits on the electrical enclosure.

Turning now more particularly to FIG. 11, depicted therein are the bipolar electrode profiles and how they react in a packed bed electrolytic cell according to a preferred embodiment. FIG. 11 further depicts bipolar electrodes that are mixed and blended to enhance their use in a packed bed and their efficiency with regard to processing quality.

Turning now more particularly to FIG. 12, depicted therein is a graph showing the energy efficiency with regard to the decomposition of metal to the hydroxide form and electrode profiles using Plates, Chips, Spheres and Fines according to a preferred embodiment.

Turning now more particularly to FIG. 13, depicted therein is an exploded view of the removable basket according to a preferred embodiment. Basket comprises titanium.

Turning now more particularly to FIG. 14, depicted therein is a cross-section of a disposable electrolytic cell with twist-off cap, quick connector and flow restrictor according to an alternate embodiment. The disposable electrolytic cell twists to lock into contact with the power source.

Turning now more particularly to FIG. 15, depicted therein is a cross-sectional view of a disposable electrolytic cell with detail of a disposable basket liner according to an alternate embodiment.

Turning now to FIG. 16, depicted therein is an Anode Mix & Anode Blend Configuration of a Packed Bed Electrolytic Cell. In order to maintain maximum cell efficiency it is important to keep the anodes free by mixing non-conductive or resistive materials with the reactive or consumable (metal) materials within the Packed bed. In this way there is a greater reaction within the packed bed which enhances the decomposition of the metal anodes to form metal hydroxides more evenly through the bed. This mixing also permits better utilization of the energy in doing its “work” of producing oxygen and hydroxyl ions within the cell.

Turning now to FIG. 17 depicted therein is an EC Cell Efficiency Analyzer, wherein hydrogen gas concentration is an indicator of cell efficiency. When the concentration of hydrogen drops below 50% of its design production, the cell is flagged to be replaced. The cell is designed to produce 200% of its effective production and therefore a reduction of 50% ensures the cell will function at 100% Oxygen produced on the Anode is generally utilized to oxidize organic compounds in the water resulting in higher DO reading in the effluent. Oxidation may be further enhanced by the introduction of air or ozone through a diffuser at the bottom of the cell.

Returning now to FIGS. 1-15, the open cell foam or sponge is fabricated from any materials that allow the metal fines to migrate throughout the cellular structure. Any sponge or open cell material is utilized that can be cut or fashioned into any shape and inserted into a housing that will accommodate the introduction of wastewater (electrolyte) and allow the bipolar electrodes to react upon application of an electric current. After impregnating, the foam is rolled around a perforated cathode which serves as the water inlet to the cartridge cell.

The metal fines comprise any metal type or non-metal material, such as, for exemplary purposes only and without limitation, machining shavings or particles that are smaller than the pore size of the cell structure in the open cell material. The cell structure holds the metal particles in place after the material is rolled into cylinder. The electrolytic sponge or basket cells hold the metal fines or non-metal material in the reactive range of the cell. Since the sponge has two sides, the interior is accessible from either side resulting in a bipolar electrode.

Disposable basket and cartridge cells hold the metal pieces and fines in the reactive zone of the cell. Bipolar electrodes have a greater surface area for the space they occupy and take less energy to decompose to a metal hydroxide than the most common plate cell configuration.

Electrolytic sponge may alternatively be utilized in a plate configured cell or in any shape to accommodate the movement of water through the sponge while introducing an electrical current through the cell.

As the anodes decompose, the cathode in the same cell is coated with a resistive film that prevents the passage of current and the decomposition of the anode over time. This coating of a resistive film takes place at a slower pace as the size of the anode decreases, resulting in complete decomposition before replacement becomes necessary (best shown in FIG. 12).

Accordingly, disposable electrolytic cells lower fabrication and maintenance costs by using low cost expendable materials. The anodes used in the disposable cells are generally produced from scrap metal chips, turnings and fines generated from machining metal parts. Small pieces of metal can be decomposed more quickly with less energy than solid plates. Efficiency in energy to decompose metal in an electrolyte (water) is directly related to the profile of the electrodes (bipolar anodes) utilized in the electrolytic cell. The more surface area exposed to the exchange of electrons, the higher the efficiency achieved in decomposition (consumption) of the metal (anode) to the hydroxide state.

To make the disposable electrolytic cells of the preferred embodiment, the open cell foam or sponge like materials are impregnated with metal fines or any conductive materials. After the sponge or open cell material is impregnated with metal fines, the sponge or open cell material is cut and/or fashioned into a selected shape and inserted in the housing, wherein the housing accommodates the introduction of wastewater (electrolyte) and permits electrical connections to the fixed electrodes.

The impregnated sponge is rolled around a fixed electrode (bar or pipe) until it forms a cylinder of the desired size to fit into the housing, much like a filter cartridge. The outside of the cylinder is wrapped with a perforated metal screen and the cartridge is inserted into the housing. The inner and outer fixed electrodes are subsequently connected to a power source.

The foregoing description and drawings comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention.

Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims. 

1. A disposable electrolytic cell comprising: at least one cathode; and at least one anode, wherein said at least one anode comprises a porous material and metal particles, and wherein said metal particles are disposed within said porous material.
 2. The disposable electrolytic cell of claim 1, wherein said porous material comprises an open cell foam.
 3. The disposable electrolytic cell of claim 1, wherein said metal particles decompose to metal hydroxide under application of an electrical current through said disposable electrolytic cell.
 4. The disposable electrolytic cell of claim 1, wherein said at least one anode is bipolar.
 5. The disposable electrolytic cell of claim 1, wherein said at least one anode is pre-blended in a basket.
 6. The disposable electrolytic cell of claim 1, wherein said at least one anode is pre-blended in a cartridge cell configuration.
 7. The disposable electrolytic cell of claim 1, further comprising a disposable housing, wherein said at least one cathode and said at least one anode are removably disposed within said housing.
 8. The disposable electrolytic cell of claim 1, wherein said at least one anode is automatically electrically connected without additional wiring by insertion into said housing.
 9. The disposable electrolytic cell of claim 1, wherein said disposable electrolytic cell comprises a packed bed electrolytic cell.
 10. The disposable electrolytic cell of claim 1, wherein said at least one anode comprises a blend of different materials in a packed bed.
 11. The disposable electrolytic cell of claim 1, wherein said metal particles comprise metal fines.
 12. The disposable electrolytic cell of claim 1, wherein said metal particles comprise scrap metal electrodes.
 13. A method of forming metal hydroxides, said method comprising the steps of: impregnating a porous material with small particles; utilizing said impregnated porous material in an electrolytic cell, wherein said small particles decompose to metal hydroxides when current is passed through said electrolytic cell from said power source.
 14. The method of claim 13, wherein said small particles comprise metal fines, said method further comprising the step of: retaining said metal fines in place in an open cell foam.
 15. The method of claim 13, wherein said small particles comprise scrap metal electrodes, said method further comprising the step of: disposing said scrap metal electrodes in a packed bed electrolytic cell.
 16. The method of claim 13 further comprising the step of: connecting said disposable electrolytic cells to a power source.
 17. The method of claim 13, further comprising the step of: passing an electrolyte through said disposable electrolytic cell.
 18. The method of claim 13, wherein said electrolyte comprises wastewater.
 19. The method of claim 13, further comprising the step of: allowing said electrolyte to flow freely through said disposable electrolytic cell.
 20. A high efficiency electrolytic cell comprising: a centrally-disposed perforated cathode; an anode, wherein said anode comprises a porous material and metal particles, and wherein said metal particles are disposed within said porous material; a second perforated cathode disposed outside of said anode; and an electrolyte, wherein said electrolyte flows within said centrally-disposed perforated cathode, and wherein said electrolyte flows via perforations in said centrally-disposed perforated cathode to said anode, and wherein said electrolyte flows from said anode to said second perforated cathode, and wherein said electrolyte exits said high efficiency electrolytic cell via perforations in said second perforated cathode. 